Pizza Carton with Webbed Corners

ABSTRACT

A carton with a generally open top and bottom end includes front and back panels foldably connected by side panels. The side panels have corner panels adapted for forming webbed corners of the carton for holding a food product in the carton.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No.60/777,295 which was filed on Feb. 28, 2006. The entire content of theabove-referenced provisional application is hereby incorporated byreference as if presented herein in its entirety.

BACKGROUND OF THE INVENTION

The present invention relates generally to a carton for holding a foodproduct. More specifically, the present invention relates to a cartonfor holding a frozen pizza.

Paperboard cartons for holding food products such as frozen pizzas areknown. The cartons typically are square-shaped and are closed at thetop, bottom, sides, front, and back to form a six-sided, fully enclosedcarton that contains the pizza and provides surface areas for printinggraphics such as advertisements or nutritional information. It isdesired to minimize the material required for existing cartons whilestill providing a full display panel for graphics. Also, it is desiredto provide a carton that has a unique appearance and shape.

SUMMARY OF THE INVENTION

In general, one aspect of the invention is directed to a carton forholding a food product. The carton comprising a plurality of panels thatextends at least partially around an interior of the carton. Theplurality of panels comprises a front panel, a back panel, at least oneside panel, at least one front connecting panel foldably connected tothe front panel, and at least one back connecting panel foldablyconnected to the back panel. The side panel has a corner panel foldablyconnected to the front and back connecting panels. The front and backconnecting panels and the corner panel cooperate to at least partiallyform a webbed corner of the carton.

In another aspect, the invention is generally directed to a blank forforming a carton for holding a food product. The blank comprises aplurality of panels comprising a front panel, a back panel, at least oneside panel, at least one front connecting panel foldably connected tothe front panel, and at least one back connecting panel foldablyconnected to the back panel. The side panel has a corner panel foldablyconnected to the front and the back connecting panels.

In another aspect, the invention is generally directed to a method offorming a carton. The method comprises providing a blank having a frontpanel, a back panel, at least one side panel, at least one frontconnecting panel foldably connected to the front panel, and at least oneback connecting panel foldably connected to the back panel. The sidepanel has a corner panel foldably connected to the front and backconnecting panels. The method further comprising forming a sleeve byfolding the blank to position the front panel in generally opposedplanar relationship with the back panel. The method comprising forming acorner of the carton by inwardly folding the corner panel so as toreduce an opening size of an open end of the sleeve.

Those skilled in the art will appreciate the above stated advantages andother advantages and benefits of various additional embodiments readingthe following detailed description of the embodiments with reference tothe below-listed drawing figures.

According to common practice, the various features of the drawingsdiscussed below are not necessarily drawn to scale. Dimensions ofvarious features and elements in the drawings may be expanded or reducedto more clearly illustrate the embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

FIG. 1 is a plan view of a blank used to form a carton according to afirst embodiment.

FIG. 2 is a plan view of the carton.

FIG. 3 is a side perspective of the carton.

FIG. 4 is a bottom view of the carton of FIG. 3.

FIG. 5 is top perspective of the carton in a partially assembledconfiguration.

FIGS. 6-9 are enlarged perspectives of a corner panel of the carton invarious stages of assembly.

FIG. 10 is a bottom end view showing a pizza in the assembled carton.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

The carton of the present invention is particularly useful in containinga food product such as a frozen pizza and providing surfaces on whichgraphics including advertising or other information may be displayed toconvey information to a consumer. It is understood that food productsother than pizza may be contained in the carton without departing fromthe scope of this invention. Further, food products contained in thiscarton may be generally round, square, rectangular, or any other shapewithout departing from the scope of this invention.

FIG. 1 is a plan view of a first, front side of a blank, generallyindicated at 1, used to form a carton, generally indicated at 3 (FIGS. 2and 3), according to a first embodiment of the invention. As shown inFIG. 2, the carton 3 is generally octagonal in shape and has four webbedcorners generally indicated at 5, 7, 9, 11. The carton 3 has an open topend 10 and an open bottom end 12. It is understood that the carton mayhave other shapes and may have fully closed top and bottom ends withoutdeparting from the scope of this invention.

The blank 1 has a longitudinal axis L1 and a lateral axis L2. The blank1 comprises a back panel 13 foldably connected to a first side panel,generally indicated 15, at a first transverse fold line 17, a frontpanel 21 foldably connected to the first side panel at a secondtransverse lateral fold line 23 and foldably connected to a second sidepanel, generally indicated 27, at a third transverse fold line 29. Eachside panel 15, 27 comprises an upper corner panel 33, 35 foldablyconnected to a intermediate portion 37, 39 of a respective side panel15, 27 at a first longitudinal fold line 41, 43 and a lower corner panel45, 47 foldably connected to the intermediate portion at a secondlongitudinal fold line 49, 51. An adhesive flap 55 comprises an upperportion 61 foldably attached to an intermediate portion 63 alonglongitudinal fold line 65 and a lower portion 67 foldably attached tothe intermediate portion along longitudinal fold line 69. As will bediscussed in more detail below, the blank 8 may be assembled into thecarton by attaching the adhesive flap 55 to the second side panel 27 bysecuring the upper portion 61 of the flap to the upper corner panel 35of the side panel, the intermediate portion 63 of the flap to theintermediate portion 39 of the side panel, and the lower portion 67 ofthe flap to the lower corner panel 47 of the side panel with adhesivesuch as glue.

The blank 1 includes four back connecting panels 73, 75, 77, 79 foldablyconnected to the back panel 13 at a respective oblique fold line 83, 85,87, 89. The two back connecting panels 73, 77 are foldably connected tothe adhesive flap 55 at the transverse fold line 57. The back connectingpanel 73 is adjacent the upper portion 61 of the adhesive flap 55, andthe back connecting panel 77 is adjacent the lower portion 67 of theadhesive flap. The back connecting panels 75, 79 are foldably connectedto the first side panel 15 at the transverse fold line 17. The backconnecting panel 75 is adjacent the upper corner panel 33 of the sidepanel 15, and the back connecting panel 79 is adjacent the lower cornerpanel 45 of the side panel. In the illustrated embodiment, each of theconnecting panels 73, 75, 77, 79 are generally triangular shaped and arelocated at a respective corner of the back panel 13. It is understoodthat the connecting panels 73, 75, 77, 79 could be other sizes andshapes (e.g., square, rectangular, etc.), without departing from thescope of this invention.

The blank 1 comprises four front connecting panels 93, 95, 97, 99similar in size and shape as the back connecting panels 73, 75, 77, 79and arranged to be in a generally mirror image arrangement with respectto the back connecting panels. The front connecting panels 93, 95, 97,99 are foldably connected to the front panel 21 by respective obliquefold lines 103, 105, 107, 109. The front connecting panels 93 and 97 arefoldably connected to the first side panel 15 at the transverse foldline 23 with the front connecting panel 93 being adjacent the uppercorner panel 33 of the side panel and the front connecting panel 97being adjacent the lower corner panel 45 of the side panel. The frontconnecting panels 95 and 99 are foldably connected to the second sidepanel 27 at the transverse fold line 29 with the front connecting panel95 being adjacent the upper corner panel 35 of the side panel and thefront connecting panel 99 being adjacent the lower corner panel 47 ofthe side panel. Each of the front connecting panels 93, 95, 97, 99 arelocated at a respective corner of the front panel 21. As described belowin more detail, the front connecting panels 93, 95, 97, 99 arepositioned to be in mirror image relationship with a respective backconnecting panel 73, 75, 77, 79 such that when the carton 3 isassembled, each of the front connecting panels and a corresponding backconnecting panel cooperate with a corresponding one of the upper cornerpanels 33, 35 and lower corner panels 45, 47 of the side panels 15, 27to form a respective webbed corner of the carton 3.

One example of a suitable method for erecting the blank 1 and loadingthe carton 3 is described in the following. As shown in FIGS. 2-5, thecarton 3 is assembled by placing the front panel 21 in generally opposedplanar relationship with the back panel 13 so that the front panel isspaced apart from the back panel by the first and second side panels 15,27. The first side panel 15 is folded ninety degrees relative to theback panel 13 along fold line 17 so that the first side panel isperpendicular to the back panel and extends upward therefrom. The frontpanel 21 is then folded 90 degrees relative to the first side panel 15so that the front panel is in generally opposed planar relationship withthe back panel 13. Next, the second side panel 27 is folded downwardrelative to the front panel 21 at fold line 29 and the adhesive flap 55is folded upward relative to the back panel 13 at fold line 57 to begenerally parallel and adjacent with the second side panel. The secondside panel 27 and adhesive panel 55 may be joined by adhesive to securethe carton 3 in the partially assembled configuration shown in FIG. 5.In this configuration the carton 3 comprises a sleeve with asquare-shaped front and back panel and an open top end 10 and an openbottom end 12. A food product P such as a frozen pizza is placed in thesleeve by sliding the pizza through the open top end or open bottom endof the sleeve. As will be discussed below, the corner panels 33, 35, 45,47 of the carton 3 are assembled to form a generally octagonal-shapedcarton with each corner panel inwardly folded to contain the pizza P orother food product in the carton.

The assembly of the lower corner panels 45 of the carton 3 will bediscussed below but it is understood that the other three corner panels33, 35, 47 are assembled in a similar manner, in accordance with theillustrated embodiment of the present invention. As shown in FIGS. 6-8,the lower corner panel 45 of the carton 3 is assembled from the sleeveshown in FIG. 5 by folding the corner panel inward at fold line 49 inthe direction of arrow A1 relative to the intermediate portion 37 of thefirst side panel 15. When the lower corner panel 45 is moved in thedirection of A1, the front panel 21 and bottom panel 13 flex to allowthe lower corner panel 45 to fold inward relative to the intermediateportion 37. As the corner panel 45 is folded inward, the front panel 21flexes upward and the front connecting panel 97 pivots at the obliquefold line 89 and the longitudinal fold line 17 as the corner panel 45 ismoved inward. In the illustrated embodiment, the connecting panel 97pivots 180 degrees from the unassembled position of FIG. 6 to theassembled position of FIGS. 9 and 10 as the corner panel 45 is movedinward in the direction of arrow A1.

The lower connecting panel 79 is pivoted in a similar manner as theupper connecting panel 97. The back panel 13 flexes downward to allowthe pivoting motion of the lower connecting panel 79 at oblique foldline 107 and longitudinal fold line 23. The lower connecting panel 79pivots 180 degrees from the unassembled position of FIG. 6 to theassembled position of FIGS. 9 and 10 as the corner panel 45 is movedinward in the direction of arrow A1. The inwardly folded corner panel 45and the pivoted upper connecting panel 97 and lower connecting panel 79form a webbed corner of the carton connecting the corner panel with therespective front panel 21 and back panel 13. At the assembled positionof FIGS. 9 and 10, the upper connecting panel 97 is folded such that aninner surface 113 of the upper connecting panel is in generallyface-to-face relation with an inner surface 115 of the front panel 21,and the lower connecting panel 79 is folded such that an inner surface121 of the lower connecting panel is in generally face-to-face relationwith an inner surface 123 of the back panel 13. The webbed corners ofthe carton may be secured in the assembled position of FIG. 10 byapplying an adhesive such as glue to the respective inner surfaces 113,121 of the upper and lower connecting panels 97, 79 to attach the upperconnecting panel to the inner surface 115 of the front panel 21 and toattach the lower connecting panel to the inner surface 123 of the packpanel 13. Attachment of the upper and lower connecting panels 97, 79 tothe respective front and back panels 21, 13 holds the corner panel 45 inthe assembled position wherein the corner panel is folded inward fromthe intermediate portion 37 of the side panel 15. Other formingconfigurations and steps for forming the carton 3 could be used withoutdeparting from this invention.

Each of the corner panels 33, 35, 45, 47 of the carton 3 cooperate witha respective front connecting panel 93, 95, 97, 99 and a respective backconnecting panel 73, 75, 77, 79 to form the webbed corners 5, 7, 9, 11of the carton. In the illustrated embodiment, the corner panels 33, 35,45, 47 are positioned at an oblique angle in relation to a respectiveadjacent intermediate portion 37, 39 of the side panels 15, 27 such thata food product, for example a frozen pizza P (FIG. 10) having agenerally circular shape, is contained in the carton 3. The inwardlyfolded corner panels 33, 35, 45, 47 of the carton 3 prevent the foodproduct from being removed from the open top end 10 or the open bottomend 12 of the carton without tearing or otherwise disassembling thecarton.

As shown in FIG. 10, the width W1 of the open top and bottom ends 10, 12of the carton 3 is less than the width W2 between the intermediateportions 37, 39 of the side walls 15, 27 of the carton. It is understoodthat the food product P may have a width approximately equal to thewidth W2 between the intermediate portions 37, 39 of the first andsecond sidewalls 15, 29 so that the food product is contained in thecarton by the inwardly folded corner panels 33, 35, 45, 47.

The pizza P is removed from the carton 3 by opening the carton at eitheror both of the top or bottom ends 10, 12 to increase the width W1 andallow the pizza to be removed from the carton. The lower corner panels45, 47 are folded outward to open the bottom end 12 of the carton 3 andthe upper corner panels 33, 35 are folded outward to open the top end 10of the carton. The carton 3 may be opened by tearing the webbed corners5, 7, 9, 11 to allow movement of the corner panels 33, 35, 45, 47 or thefront connecting panels 93, 95, 97, 99 may be separated from the frontpanel 21 and the back connecting panels 73, 75, 77, 79 may be separatedfrom the back panel 13 to allow movement of the respective corner panel.

In one embodiment, the food product P is a round frozen pizza having adiameter of approximately 11.5 inches. The carton 3 has a width W2between the intermediate portions 37, 39 of the side walls 15, 29 ofapproximately 11.5 inches, a height H1 (FIG. 2) between the open top andbottom ends 10, 12 of approximately 11.5 inches, and a width W2 of theopening at the top and bottom end of approximately 6.5 inches. It isunderstood that the dimensional information provided herein is exemplaryand is not intended to limit the scope of the invention. Further, thefood product P could have shapes other than circular (e.g., square,rectangular, etc.) without departing from the scope of this invention.

It is understood that various sizes of pizzas P or other food productsmay be housed in the carton 3 and that graphics including advertising orother information may be printed on the outer surfaces of the back panel13 and the front panel 21, and the side panels 15, 27 to conveyinformation to the consumer. The carton 3 of the illustrated embodimentis free from any overlapping end flaps at the top and bottom ends 10, 12and uses less material than conventional six-sided cartons that fullyenclose the pizza. The shape of the carton 3, being generally octagonalin plan view of the illustrated embodiment, provides the carton a uniqueshape to distinguish the carton from conventional square or rectangularcartons.

As shown in FIG. 2, the food product P is hidden from view within theinterior of the carton 3; therefore, the food product is schematicallyillustrated by dashed lines.

In the exemplary embodiment discussed above, the blank is formed fromclay coated paperboard, typically having a caliper of at least about 18,so that it is heavier and more rigid than ordinary paper. The blank, andthus the carton, can also be constructed of other materials, such ascardboard, or any other material having properties suitable for enablingthe carton to function at least generally as described above. The firstand second sides of the blank can be coated with, for example, a claycoating. The clay coating may then be printed over with product,advertising, and other information or images. The blank may then becoated with a varnish to protect any information printed on the blank.The blank may also be coated with, for example, a moisture barrierlayer, on either or both sides of the blank. The blank can also belaminated to or coated with one or more sheet-like materials at selectedpanels or panel sections.

The term “line” as used herein includes not only straight lines, butalso other types of lines such as curved, curvilinear or angularlydisplaced lines.

The above embodiments are described as having one or more panels adheredtogether by glue. The term “glue” is intended to encompass all manner ofadhesives commonly used to secure carton panels in place.

In accordance with the exemplary embodiments, a fold line can be anysubstantially linear, although not necessarily straight, form ofweakening that facilitates folding therealong. More specifically, butnot for the purpose of narrowing the scope of the present invention,fold lines include: a score line, such as lines formed with a bluntscoring knife, or the like, which creates a crushed or depressed portionin the material along the desired line of weakness; a cut that extendspartially into a material along the desired line of weakness, and/or aseries of cuts that extend partially into and/or completely through thematerial along the desired line of weakness; and various combinations ofthese features. In situations where cutting is used to create a foldline, typically the cutting will not be overly extensive in a mannerthat might cause a reasonable user to incorrectly consider the fold lineto be a tear line.

The foregoing description of the invention illustrates and describesvarious embodiments of the present invention. As various changes couldbe made in the above construction without departing from the scope ofthe invention, it is intended that all matter contained in the abovedescription or shown in the accompanying drawings shall be interpretedas illustrative and not in a limiting sense. Furthermore, the scope ofthe present invention covers various modifications, combinations,alterations, etc., of the above-described embodiments that are withinthe scope of the claims. Additionally, the disclosure shows anddescribes only selected embodiments of the invention, but the inventionis capable of use in various other combinations, modifications, andenvironments and is capable of changes or modifications within the scopeof the inventive concept as expressed herein, commensurate with theabove teachings, and/or within the skill or knowledge of the relevantart. Furthermore, certain features and characteristics of eachembodiment may be selectively interchanged and applied to otherillustrated and non-illustrated embodiments of the invention withoutdeparting from the scope of the invention.

1. A carton for holding a food product, the carton comprising: a plurality of panels that extends at least partially around an interior of the carton, wherein the plurality of panels comprises a front panel, a back panel, at least one side panel, at least one front connecting panel foldably connected to the front panel, and at least one back connecting panel foldably connected to the back panel; with the side panel having a corner panel foldably connected to the front and back connecting panels, wherein the front and back connecting panels and the corner panel cooperate to at least partially form a webbed corner of the carton.
 2. The carton of claim 1 wherein the front connecting panel is in generally face-to-face relation with the front panel and the back connecting panel is in generally face-to-face relation with the back panel.
 3. The carton of claim 1 wherein the side panel has an intermediate portion, the corner panel is an upper corner panel, and the side panel further comprises a lower corner panel foldably attached the intermediate portion.
 4. The carton of claim 3 wherein the side panel is a first side panel and the carton further comprises a second side panel having an intermediate portion, an upper corner panel foldably attached to the intermediate portion of the second side panel, and a lower corner panel foldably attached to the intermediate portion of the second side panel.
 5. The carton of claim 4 wherein the carton comprises four front connecting panels and four back connecting panels.
 6. The carton of claim 5 wherein each front and back connecting panel is respectively foldably connected to one of the front panel and the back panel at an oblique fold line.
 7. The carton of claim 6 wherein each of the front and back connecting panels is respectively foldably connected to one of the upper corner panels and lower corner panels at a lateral fold line.
 8. The carton of claim 5 wherein the carton comprises four webbed corners and each of the upper and lower corner panels respectively cooperates with an adjacent front connecting panel and an adjacent back connecting panel to form one of the webbed corners.
 9. The carton of claim 1 wherein each of the front and back connecting panels is generally triangular.
 10. The carton of claim 1 wherein the carton has an open top end.
 11. The carton of claim 1 wherein the carton has an open bottom end.
 12. The carton of claim 1 in combination with a food product, wherein the food product is positioned in the interior of the carton.
 13. A blank for forming a carton for holding a food product, the blank comprising: a plurality of panels comprising a front panel, a back panel, at least one side panel, at least one front connecting panel foldably connected to the front panel, and at least one back connecting panel foldably connected to the back panel; wherein the side panel has a corner panel foldably connected to the front and the back connecting panels.
 14. The blank of claim 13 wherein the front and back connecting panels and corner panel are for cooperating to at least partially form a webbed corner when the carton is formed from the blank.
 15. The blank of claim 13 wherein the side panel has an intermediate portion, the corner panel is an upper corner panel, and the side panel further comprises a lower corner panel foldably attached the intermediate portion.
 16. The blank of 15 wherein the side panel is a first side panel and the carton further comprises a second side panel having an intermediate portion, an upper corner panel foldably attached to the intermediate portion of the second side panel, and a lower corner panel foldably attached to the intermediate portion of the second side panel.
 17. The blank of claim 16 wherein the blank comprises four front connecting panels and four back connecting panels.
 18. The blank of claim 17 wherein each front and back connecting panels is respectively foldably connected to one of the front and back panels at an oblique fold line.
 19. The blank of claim 18 wherein each of the front and back connecting panels is respectively foldably connected to one of the upper corner panels and the lower corner panels at a lateral fold line.
 20. The blank of claim 13 wherein each of the front and back connecting panels is generally triangular.
 21. A method of forming a carton, the method comprising: providing a blank having a front panel, a back panel, at least one side panel, at least one front connecting panel foldably connected to the front panel, and at least one back connecting panel foldably connected to the back panel, with the side panel having a corner panel foldably connected to the front and back connecting panels; forming a sleeve by folding the blank to position the front panel in generally opposed planar relationship with the back panel; and forming a corner of the carton by inwardly folding the corner panel so as to reduce an opening size of an open end of the sleeve.
 22. The method of claim 21 wherein the forming of the corner comprises: pivoting the front connecting panel to be in face-to-face relation with the front panel, and pivoting the back connecting panel to be in face-to-face relation with the back panel.
 23. The method of claim 21 wherein the end is a top end, the corner is a top corner, the corner panel is a top corner panel, the front and back connecting panels are top front and back connecting panels, and the blank comprises a bottom corner panel foldably connected to bottom front and back connecting panels, and the method further comprises forming a bottom corner by inwardly folding the bottom corner panel to reduce an opening size of an open bottom end of the sleeve.
 24. The method of claim 23 wherein the side panel is a first side panel, the blank further comprises a second side panel having a top and a bottom corner panel, the top corner is a first top corner, the bottom corner is a first bottom corner, and the method further comprises forming a second top corner of the carton by inwardly folding the top corner panel of the second side panel.
 25. The method of claim 24 further comprising forming a second bottom corner by inwardly folding the bottom corner panel of the second side panel.
 26. The method of claim 21 further comprising inserting a food product into the sleeve.
 27. The method of claim 26 wherein the food product is inserted into the sleeve prior to the forming of the corner.
 28. The method of claim 26 wherein the food product is inserted into the sleeve after the forming of the corner. 